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MEAT PROCESSING

INTRODUCTION

In India's almost the entire production of meat is marketed in the fresh state. Meat [Piggery, Chicken] Processing and pork and very small quantities of motton and beaf are preserved and processed into different products.

There are several small units scattered all over the country producing annually about 100-150 tonnes of various types of meat products. There is scheme for setting up twelve Beacon factories in the public sector.

When the question of nutrition is studied from a national view point, manufacture of piggery products can be said to be of high importance. Piggery products are used mainly as food for poultry farming as well as the breeding of cattle. Piggery products is extensively used throughout the world because it considerably contributes to improvement in egg-laying as well as to enhancement of the nutritious value of eggs and meat.

Being a dried product piggery products are very convenient for transport. There is no fear of decay in transport. Furthermore, as the moisture content is small, it can be transhipped to far distant places by sea at low freight rates.

USES & APPLICATIONS

The Meat [Piggery, Chicken] products as mentioned under product introduction find number of uses.

1. The production are mainly used as foodstuffs
2. It cannot be used directly as food for man.
3. Piggery, chicken, meat products are extensively used throughout the world.
4. Processed piggery products, chicken, meats are used throughout the world.

MARKET POTENTIAL

The principal animals slaughtered for meat in India are sheep, goats, buffaloes. pigs, frogs and cattles.

Mutton (Sheep), veal and goat fresh are generally grouped into one category in the meat market through generally it has been observed that meat eating population in India prefer to eat goat flesh and therefore it fetches better price than mutton. Beef (includes bevine meat) in India is considered to be much inferior in quality and does not fetch a good price in the indigenous market. Pig raising and the pork is lower than that of beef and mutton and goat flesh.

Export of Meat and Meat Products

Meat is a highly export oriented item. Varieties of meat exported by India are meat of sheep, goat and culled buffalo in fresh, Frozen, frog legs are considered to be a delicacy item and have great export potential.

Exports of Processed/Preserved Meat

Processed meat products mainly consist of pork and pork products such as ham, Bacon, sausages etc.

Problem of Meat Industry

In terms of liverstock, India has probably the world's largest livestock resources, but it is still way behind the other nations supplying meat in the world market. The quantity of meat produced is far below the requirements and suitable meat breeds of liverstock have not yet been developed.

PRESENT MANUFACTURERS

Some Manufacturers of Most Products in India are as follows :-

1. M/s. Brooke Bond India Ltd.,

P.O. Box 96,

Aurangabad - 431 001.

2. M/s. Central Daily Farm.,

Aligarh,

Uttar Pradesh.

3. M/s. Dr. Writers Chocolate & Canning Co.,

Bhavani Sankar Road,

Dadar,

Bombay -400 028

4. M/s. Essex Farms Pvt. Ltd.,

Aurbindo Marg,

New Delhi - 110 016.

India Exporters of Meat and Meat Products

1. M/s. Kalvery & Co.,

Mazagaon Road,

Bombay - 400 010.

2. M/s. Gits Food Products (India),

Hadapsar Indl. Estate,

Poona - 13.

3. Iseland Club Canning Co.,

P.B. 1712,

Cochin - 16.

4. MAFCO,

Minitry Bhavan,

D.Vachaa Road,

Bombay - 400 020.

Importers of Meat and Meat Products Abroad

1. M/s. Conga Amalgamated,

508, Nicholson Street,

Nth Fitzroy Victoria 3068,

Australia.

2. The Food & Serverages Corporation,

326, Maha Bandools Street,

Rangoon,

Burma.

3. M/s. Flamingle Trading Co.,

1604, Landwise Commercial Building,

118 - 120, Austus Road,

Kowloon,

Hong Kong.

4. T.A. Hamid Marker & Sons.,

42, Erickflods Road,

Ist Floor,

Kuala Lumpur,

Malaysia.

PROCESSING TECHNIQUES MEAT PROCESSING

Besides freezing, the processing techniques in rogue today are curing, smoking, canning, dehydration and irradiation. The following processes :-

Curing

It is the simplest form of meat preservation/Piggery/Chicken used since concient times and originally involved merely mixing of salt to Meat/Piggery/Chicken later on colour and flavour development became part of the curing process. Curing is done by applying salt, sodium nitrate, and sugar to meat. Salt acts as preservative, extracts water and makes the meat hand and dry, sugar softens and neutralizes the harshness of salt and improves the flavour, and sodium Nitrate improves the colour and helps maintain the attractive reddish or pink colour of the meat. Now in this world due to hi-technology of refrigeration, curing today is valued more as a method for providing better flavour and colour to meat rather than an a method for providing better flavour and colour to meat rather as a method of preservation. Curing of meat may be done by sweet/pickle curing, dry-salt curing, dry-sugar curing and Injection curing. The first process, is mostly used for curing ham and its cuts. The meat is kept in large watertight vats with a mixture of slat, sugar or similar sweetness and a small quantity of sodium nitrate and the temperature is maintained at 2-4.5oC for 15-45 days. Bacon pieces are cured by a brine of 15-17o Be, Whereas hams and other thick pieces are preserved with brine of 20-25o Be;'

In dry-salt curing, salt is rubbed on the surface of the meat which is then stacked with salt all around. This is generally used for preserving some of the heavier cuts. The dry sugar curing is used for bacon and other cuts where mild cure is required. In this method the meat is packed very lightly into watertight containers with a title sprinkle of salt, sugar and Sodium nitrate between the layers so that the cuts yet cured in their own juices.

Chicken an turkeys are sometimes cured and smoked, and the products are considered a delicacy.

The curing effect are enhanced by the used of chemicals such as ascorbic acid, isoascorbic acid and their sodium salts, and phosphates. Ascorbic acid and phosphates help in suppression of oxideation which heads to rancidity and loss of flavour and colour. Monosodium glutamate and hydrolysed proteins are used for enhancing or intensifying the flavour of cured meats.

Additions used for Meat

Processing - (i) Ascorbic Acid and (ii) Isoacscorbic Acids and Their salts, butylated hydroxy anisole (BHA), ammonium hydroxide, hydrochloric, lactic, phosphroric & tartaric acids, stearoyl citrate etc, gases like ozone and carbon dioxide and some colouring agents are also used as preservatives.

Smoking - Many meats like ham and bacon are smoked in addition to being cured to improved the keeping quality of the products without refrigeration and to make them more palatable. Smoking alters the appearance of the meat to the great extent, and imparts a rich brown colour and a characteristic mild sweet flavour.

The cured cuts and usually washed with water before smoking. Smoking is carried out in smoke houses in which temperature, humidity, and circulation and denseness of smoke can be controlled. The heat is supplied by gas burners, electric heaters, or wood smoke, and the temperature of smoking is usually maintained below 46oC. The smoking time and temperature differ according to the products.

Smoking reduces the surface bacterial population of the product.

Dehydration - The meat alices are brined in to per cent saline solution for 3 minutes, spread out on trays and dried for 8-10 hours in dehydration tunnels maintained at 63-68oC. The alices appearing as flakes are packed in tins, salted and sealed. Each tin is perced to provide a small hole, then kept in a hot chamber (71oC) for 3 hours and the hole sealed. The entire process from slaughtering to packing of dehydrated meat takes about 22 hours. Dehydrated most, however, has its own limitations and is not very popular with consumers.

Canning- Canning is the most popular method of preservation for both raw and cooked meats. Fresh beef, pork, cesl, lamp and some of the offals are well adapted to cannings.

The amount of heat or the time and temperature required for the destruction of micro-organisms depend on the nature of the product, its PH, presence of curing salts, and shape and size of the can. Some products are packed hot into the can and others cold. They are packed in lacquered or unlacquered cans, in lithographed cane to obyiate labelling.

Irradiation-Preservation of food by Irradiation is of recent introduction. Infrared rays have no effect on sterilization of meat. Ultraviolet rays of wave-length from about 2,000 to 2,900. A exhibit bacterioidal action.

SALT

There are various grades of salt, from rock slat to the purest stored vacuum slat, the latter having been freed from most of the inpurities, such as calcium salts, produce undesirable results in meats packed in glass. A high mineral impurity in salt is very liable to assist the formation of "white foots" in glasses of tongue, etc.

The use of the commoner salts, having a high bacterial contant, may cause trouble, Owing to the temperatures involved during manufacture, the finest salts-that is, the stored vacuum salts-are practically free from bacteria. Hence it is recommended that for highclass work, especially in the preparation of foods in glass, only staved vacuum salt of 99.5 to 99.7 per cent sodium chloride should be used.

Recently a new type of salt, referred to as "dendritic" has been produced. It has the advantage of being extremely light and consequently when mixed with dry seasoning does not tend to separate out. As this type of salt goes into solution very rapidly, it has been found of considerable value in treatment of sausage consings.

Meat Curing

Sodium nitrite is used as a curing and preserring agent in bacon, ham frank furters, etc. Brines containing Sodium nitrite inhibit the growth of bacteria including clostridlum botulinum. The maximum allowable quantity of Sodium nitrite in the brines and the residual remaining in the meat is under the jurisdiction of FDA and USDA.

Citric Acid may be used in canned vegetables to lower PH, to reduce heating requirements and to inhibit the growth of microorganisms.

Refrigerated Storage of Meat- Being highly perisheable, meal can be kept only through proper recessing or in cold storage. When meat gets spoiled, it becomes shiny or sticky, turns dark brown and develops an unpleasant smell and teste.

In India, raw meat is mostly sold fresh and is not ordinarilly stored in any appreciable quantity. It is sometimes stored for 12-36 hours in ice during warm weather mechanicla refrigeration facilities are available only in major cities. Cold storage is used on an extensive scale in western countries for the storage of meat and its products for long periods.

Storage of meat at chilling temperatures above the freezing of meat is known as refrigerated storage, and that below the freezing point as frozen storage. Optimum conditions for chilling of carcasses are -1.0o to + 1.5oC and relative humidity of 88-92 per cent. For storing meat for long periods, frozen storage is used and the temperatures recommended are -23o to 18oC. Meat may be frozen in whole carcasses, in large cuts or as consumer cuts. It is usually wrapped and packed in fibreboard or wooden boxes before freezing. The two methods of freezing and commercially adopted now a days are blast freezing and plate freezing, the former being used for irregularly shaped items like beef quarters and small carcasses and the latter for items of regular shape. Both these methods freeze the material fast and are preferable to slow freezing of chilled meat in still air at -10o to 15oC, since the drip on thawing and consequent loss in soluble nutrients and consumer appeal are much less in soluble nutrients and consumer appeal are much less in quick-frozen meat, Storage life of frozen meat and meat products kept at -18oC is as follows: beef, 6-18; lamb, 6-16; ceal, 4-14; pork, 4-12 chopped beeg, 4-6; pork a sausage, 2-6; smoked ham and bacon, 4; and beef liver 2-4 months. Polutry -The dressed caracass is chilled immediately to below 4.5oC and then held at nearly 0oC. Chilling of polutry may be done by slush ice to bring down quickly the body temperature of the cracass within 2-8 hours and to prevent excessive desication of further storage. The chilled product keeps well for 3-4 weeks. Treatment of dressed and eviscerated birds with chlortetracycline or oxytetracyline (10 ppm) during chilling prolongs the storage life.

Ham

Trimmed pork legs (ham) are first subject to injection curing. For this purpose two types of pickles, pump pickle and cover pickle are prepared from common salt, sugar, saltpetre, and water at a temperature of 4.5oC. The legs are given 4-6 stiches of pump pickles.

After being rubbed with some dry salt, the injected material is kept in the cold store at 4.5oC for 1-2 days, followed by inmersion in the cover pickle till curing is complete. The ham pieces are turned frequently during cover pickling at least at an interval of 3-4 days to ensure picling least at an interval of 3-4 days to ensure uniform penetration of pickle. The cured material is matured at 4.5-7oC. It is then washed in running waster to remove excess of slats, cleaned thoroughly of excess fat and irregular trimmings, and hung to drain off the water. The drained material is transferred to the smoke house.

Sawdust from hardwood is spread on the floor of the smoke house and ingited; it is not allowed to smoulder. The absorption of smoke and change in colour of the outside surface of smoked ham is hastened by high temperature. The process takes about 18 hours to complete with a smoke house temperature of 51-57oC. The smoke ham is cooled to room temperature before keeping in the cold store at a temperature of 7.2oC.

PROCESS FLOW SHEET OF MEAT PRODUCTS

SUPPLIERS OF PLANT & MACHINERY

1. Abhinav Machine Co.,

388, Sambhar Road,

Sangli - 16.

2. Crescent Iron & Steel Corpn. Ltd.,

Indl. Estate, Lalbagh,

Bombay -12.

3. Jai Mata Engg. Works.,

8006, Multani Dhanda,

Eleven Quarters

Paharganj,

New Delhi - 55.

4. International Combustion Ltd.,

101, Park Stree,

Calcutta -16.

5. Jayens Engg. Co.,

Warden House Sir. P.M. Road,

Bombay - 1.

6. Joshi Industrial Corporation,

Loha Bhavan,

Peter D'Mello Road,

Bombay -9.

Disintegrators

1. Modern Foundry & Machine Works,

Ahmednagar,

2. S.P.Engg. Corpn.,

77, Fazalganj,

Kanpur.

3. M/s. Gandhi Engg. Corpn.,

62/1A, NS road,

Calcutta - 1.

Mixer

1. M/s. A.P.V. Engg.Co. Pvt. Ltd.,

2, Jessore Road, Dum-Dum,

Calcutta - 28.

2. M/s. Anup Engg. Ltd.,

Anil Starch Premises,

Anil Road,

Ahmedabad - 2.

Boilers

1. M/s. Tempo Indl. Corpn.,

Lamington Chambers,

Lamington Road,

Bombay - 4.

Tanks

M/s. A.P.V. Engg. Co. Pvt. Ltd.,

2, Jessore Road, Dum Dum,

Calcutta - 28.

M/s. Bando & Co. Pvt. Ltd.,

S.N. Bando House,

25, Ganesh,

Chandra Avenue,

Calcutta - 13.

M/s. Barakar Engg. & Foundary Works Ltd.,

Hapar House 25,

Brebourne Road,

Calcutta - 1.

ADDRESS OF IMPORTED MACHINE

For Minear

John Laska U Schne,

Gesellschaft mbH,

Invalidenstrasse 5

B-aumgaese 68

A 1031 Wien 3

Telephone : (0222) 733504

Telex : 131418.

FOR IMPORT OF MACHINES

1. Export Promotion Council for Processed Foods,

105, New Delhi House,

Barakhamba Road,

New Delhi - 1.

Can provide you information on the scope for export of the products under consideration, thus helping in the import of machinery required under Govt. Export promotions scheme.

2. Export & Import Council,

Central Govt. Department,

Udyog Bhawan,

Zinea Azad Road,

New Delhi - 11.

Will providing necessary sactions regarding the import for the machine if require to import.

3. Chinnar Exports Pvt. Ltd.,

101-A, Surya Kiran,

Kasturba Gandhi Marg,

New Delhi - 1.

Could be help in the respect of import and export requirements.

REQUIREMENT FOR OLD STORAGE

The following concerns dealing in refrigeration and Air conditioning will provide complete information on cost and requirement for cold storage.

1. Jindal Refrigeration,

26, Netaji Subhash Marg,

New Delhi - 2.

2. Allied Air conditioning Corp (Regd),

70, Najafgarh Road,

New Delhi - 15.

3. Hindustan Refrigeration Stores,

4, Netaji Subhash Marg,

New Delhi - 2.

4. Goyal Refrigeration Engg. Co.,

Lajpat Nagar,

New Delhi - 24

PLANT ECONOMICS

Basis

1 Ton Piggery Products.

3 Ton Meat Products.

1 Ton Processed Chicken Products.

LAND & BUILDING

PLANT & MACHINERY

OTHER FIXED ASSETS

FIXED CAPITAL

WORKING CAPITAL REQUIREMENT/ANNUM

RAW MATERIALS

SALARY & WAGES / ANNUM

UTILITIES AND OVERHEADS

Total load is 55 Kwatts

TOTAL WORKING CAPITAL/ANNUM

COST OF PROJECT

TOTAL CAPITAL INVESTMENT

COST OF PRODUCTION/ANNUM

TURN OVER/ANNUM

BREAK EVEN POINT (B.E.P)

Fixed Costs of the plant are as under :-

LAND MAN RATIO = Total land / Manpower

800 : 25 :: 32 : 1

RESOURCES FOR FINANCE

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